5+ Things Every Suzuki Samurai Enthusiast Does

MY explains how to fix the common issues with most Suzuki Samurai 86-95 USA models.
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Https://Acksfaq.com has the reverse polarity circuit board for LED. He even has a board with the clicky start relay fix included.
Don Cheek sells LED headlights, LED pods and bar lights [e-mail]
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[@ronnjerremy5796]

Awesome vid you sound like the dude from big lebowski

[@deadbrother5355]

There's no question. Its the dude. The dude abides.

[@TrailGoon87]

that's just like...your opinion man...

[@jasoncampbell5847]

I live in KY, had and 88.5 stock samurai when I met my wife. Her BFF also had one but was cheaply set up on 33's. We were married within 6 months, had 3 kids and i sold my samurai because I started driving a truck for Toyota of Georgetown KY 1.75 hrs from home. I rebuilt cars and trucks for 10 years to drive back and forth while putting her through school and our oldest son at 17 had a car accident that left him paralized with a brain injury. I quit my job that day and went home to take care of him. Sold almost everything I had to stay alive and bought a $2,000 samurai to drive in order to get back and forth to college to become a Physical therapist assistant. One day a fellow student was following me in my Suzuki and commented that he always wondered why I always smelled like gas. I didn't realize but talked to you several times and you talked me through a full rebuild. I thank you Sir for helping me through a very trying time in my life. I recently picked up a 1986 pretty solid but not running and will be putting it together for my kids and grandkids to learn to drive stick. Sorry for the long comment but it just means that much to me.

[@warspirit9488]

Get a 1.9 TD VW engine for the best power plant.

[@Chris-zp2ni]

I just picked up a stock 1988.5 and plan to do just that!

[@xtinmanx]

I’ve always wanted a samurai. Maybe one day. I don’t even know why I watched all the way thru.

[@Zuksoffroad]

It’s a cult thing. Like hot rods, motorcycles, boats, and a thousand other things. Some get it and understand that a old Bronco can be six figures and a rougher ride.

[@charlestiffany1526]

Thanks for explaining the grounds and the horn fix. Also the good spark.

[@Zuksoffroad]

Glad to help

[@GusmaroPompa-tj7hk]

I have 1973 Suzuki jimmy I need the transfer case if someone have one please contact me

[@Zuksoffroad]

Be specific about the model. Can you confirm this is a 3 cyl engine and a divorced miniature t-case. Called an LJ

[@shankarbalan3813]

These are superb. In India they are called the Gypsy. And have been here since 1985. Our Armed Forces and Police and Forestry Services swear by these.

[@manitobaman5588]

Very straight forward and practical. I have a Vitara 4 door and its my little tractor.

[@speedfreak8200]

Wish I knew about the ground for the lights. I cleaned up the horn contacts with no luck, I wired a 4 pin automotive relay and horns have been loud and proud ever since. I switched from Jeeps to Sammy's mid 90's but you learned me some, thx

[@luthars485]

Gotta live how this cars are getting the love they deserve recently

[@jeffjames1746]

Webers are fine with proper setup and tuning. I've ran one on my 87 since 88. 32/36 on the original 1.3 and then on the 1.6 8v I installed in 2003. Rebuild the 1.6 with some mods in 2013 and switched to a 38 "Outlaw". Runs awesome on road and performs good off road with my set up. I use low pressure pump with a return line style filter. Mounted the carb backwards on a modified 1.6 TBI intake and use plastic float with the lowest setting that doesn't starve the engine under full load. Jetting is fine tuned, ignition is 14 initial and 32 total and running vacuum advance. Ported and .020 shaved head, .020 block, and 260 cam. Running the same Thorley header I've had since 88. 4.16 TC, stock diffs, turning 30x9.50/15s.

[@Zuksoffroad]

There are a few people that like them. Please text me a picture of your spark plugs.

[@samaxeman123]

I bet that thing sounds awesome

[@Tonnsfabrication]

We run three sammis with webers and we wheel pretty hardcore stuff without issues. They run so well I did'nt even know they ever had issues. It may be the type of wheeling and not so much all of off roading in general?

[@Zuksoffroad]

@@Tonnsfabrication I always ask for pictures of a spark plugs on a nice running Weber. I am happy they work for you. Black and sooty isn’t good for the engine.

[@donaldg9310]

@Zuksoffroad thanks for all this information. We conquered the blue spark the other night. Now I think you addressed all the rest of my issues here. What a great wealth of knowledge you have. Unparalleled support in the industry. My greatest appreciation goes out to you good man.

[@Zuksoffroad]

Always MY pleasure

[@richardwest2505]

I love the videos and all the knowledge

[@CJ-gk8jb]

Love watching your videos, I appreciate your work. Thank you for your contributions to the zuk community for all these years. I just picked up a rig, and I live in Payson, and just learned all about your business and everything. I would love to visit some time. (I wish i had the financial backing to work with you, i would love to have an offroad rental focused on the samurai/jimny's so i could build a cashflow model that would pay for the shop's R&D, and keep a yard full of sammies lol.) I'm sure we will meet some time! I like stuff that go vroom and you are the guy that does samurai stuff.

[@chuckhardin1425]

Ive been zukin since 04 and i never heard about most of these things till now👌. New subscriber 🤙

[@Zuksoffroad]

Welcome aboard!

[@rggl3438]

I bet this guy must know the Suzuki better than his wife both personally and intimately😅

[@Zuksoffroad]

Not true. Coming up on fifty years married to my south Pasadena blonde.

[@joesgonefishin4789]

Bit of an odd one, but any tips to illuminate the fan settings? Can't see what I'm doing at night

[@Zuksoffroad]

Round dash you can still get control panels with clear lenses. Replace the bulb and make sure dimmer is turned up

[@LeFraudHasChokedInSIXFinals]

To get the horn working you may have to remove the steering wheel and clean the contacts on the back side as well.

[@Zuksoffroad]

This is true. Just not as likely being inside the steering column. The good news is the steering wheel comes off easy enough with a puller. We have to pop a lot off to straighten them out.

[@ZUKME]

Awesome! Thanks for this. Just found your channel :)

[@Zuksoffroad]

Awesome! Thank you!

[@reneguay1347]

I have a 91 samurai do you know where i can get a 2 piece soft top

[@Zuksoffroad]

I can’t say I have ever seen a two piece fabric top.

[@jarjr63NY]

Awesomeness 😊

[@tokinwithtuck]

thanks

[@oscarjuarez6366]

The corroded bullitt off the filter did wonders! Amazing, thank you.

[@Zuksoffroad]

You're welcome!

[@eldrickejleest]

What does the noise filter look like?

[@Zuksoffroad]

@@eldrickejleest text me for a picture 714 488 2272

[@charlestiffany1526]

You talked about the sone light, what do you suggest when you can remove your doors? I just removed the switch and don’t use the sone light. But sometimes I get that high beam height on the dash.

[@Zuksoffroad]

Take the wire going to the door switch and ground it thru a switch. Will only work with new switch or switch on dome lite . Text for tech support, won’t take two days to respond. 714 488 2272

[@subhanalibhatti]

Hello please can you tell me where is the chassis number and chassis plate located on this jeep? Please tell

[@Zuksoffroad]

I do not do Jeeps. Suzuki Vehicle Identification numbers (VIN) vary from model to model. Many numbers are etched into the frame in front of the front tire. What model do you have?

[@dylanwallace5571]

Is there any mods to improve hp and torque gains to improve the wheel speed

[@Zuksoffroad]

To the engine yes Engine swaps Boost engine Improve flow from carb to the tail pipe. Is there something cheap that makes an engine work better? Maintenance. Rebuild if compression is low. These are high compression numbers for peak performance. 175 per cylinder Adding larger tires makes the small 1.3 sluggish. Gears in the t-case will help top end speed as well as slower in low. It’s your use of the car that dictates my advice.

[@Mrdub-tn4eg]

Feel like a badazz fixing my horn too easy

[@Zuksoffroad]

Well you are if you fixed the beep beep

[@foowashear23]

Hey, getting ready to tear my samurai apart any good videos out there on getting to the engine

[@Zuksoffroad]

One of the easiest to pull. Text me my cell is on homepage of website. In 5 minutes you will know how we do it.

[@cwilliams4378]

Can the sidekick noise filter be retrofit to the samurai?

[@Zuksoffroad]

The three wire can the four wire cannot. Same colors Brown/white Brown Black often with green bands.

[@DirtyHandsRob]

I have the old battery clamps. What would you suggest for new ones?

[@Zuksoffroad]

O’riely’s has molded cables with leads for ground and power. Usually $23 gets both Neg and Pos

[@DirtyHandsRob]

@@Zuksoffroad awesome. Thanks

[@mihalyhever8181]

Thank you for this informations from Hungary.

[@Zuksoffroad]

Glad it was helpful! God Bless Hungary

[@mathewsren9712]

Excelente video!

[@chuckfinley3152]

Awesome

[@biologicalboutique407]

Looks like you shot this in the Verde Valley.

[@Zuksoffroad]

Gods Rock Crawling Country Yavapai County The Verde Valley!

[@jacklandismcgowan1413]

Thank you for all of that information. I recently did the ecm wiring delete following your KZbin video . Finished up and my Sami ran like a top. Last week I started fixing rust areas under the windshield and took out the dash. I went to start the Sami and I have nothing….not starting, not turning over. I’ve just finished checking and cleaning the main battery ground. This video came at a perfect time. I’m going check all the wiring that you mentioned. Thanks Again 👍👍👍😎

[@jacklandismcgowan1413]

Let me add to the above problem. I tried to start it with the push button start from the battery to the starter…nothing. Battery is less than a year old reading about 13.5 volts.

[@Zuksoffroad]

Nice work!

[@lovett1200]

Thanks for a great video...

[@Zuksoffroad]

Glad you liked it!

[@RalphAting]

very informative. thank boss. gonna do the grounding and tidy up all the cable as it goes. battery terminal i might just change into something more convenience.

[@Zuksoffroad]

Appreciate the effort!

[@RalphAting]

Can you explain about carburetor more. If we install new one aftermarket. Explain the old carburetor hose n cable.then the new one, which hose goes where..

[@Zuksoffroad]

@@RalphAtingthat would be a no. All this information is at acksfaq.com

[@Z-Bart]

That white one is nice. Is it for sale?

[@Zuksoffroad]

These days the Samurais sell before we advertise them when we have for sale.

[@jeffreycote1182]

What NGK spark plugs would you use for a 1987 1.3 liter?

[@Zuksoffroad]

BPR5ES

[@jeffreycote1182]

Also what is the gap for those?

[@Zuksoffroad]

Minimum .030” Max .032”

[@brandonboulton2776]

Wish I could borrow your brain for a day with my truck. I've got a 1988 Suzuki Carry db71t F5A KEI truck. I upgraded the points to a custom pertronix. Rebuilt the engine completely. Deleted the EGR. Ported and polished the intake manifold. Upgraded the carburetor to a grizzly 660 carburetor. Gave it a 2 inch lift kit. Bigger wheels and tires from a Datsun 240z (bolt pattern is right). Etc... Definitely need some noise capacitors but I'm not positive how to hook em up. Electric is my kryptonite. I did upgrade all my lights to LED. Blessings 🙏

[@Zuksoffroad]

I would have done it differently. The stock spark is incredibly good.

[@brandonboulton2776]

@@Zuksoffroad I still have a points distributor for backup.

[@brandonboulton2776]

@@Zuksoffroad what would be a better route? I'm looking for maximum durability.

[@Zuksoffroad]

@@brandonboulton2776 there are no points in a factory distributor. Just a magnetic switch and an ignitor. Super reliable. When grounded thru the factory noise filter you get a super nice blue spark. I have no idea what a grizzly 660 carb is. If you have 100 miles on send me some pics of the spark plugs. I am sure they are lean for a high performance engine. My cell phone is on the website home page. So is my email. I prefer not to get into thousand word tech conversations on SM.

[@brandonboulton2776]

@@Zuksoffroad I'm not sure you read my comment. Suzuki Carry db71t F5A. 543cc 3 cylinder. Came stock with points. All of em did. I had pertronix build me a custom upgrade.

[@ecowboys193]

Having an issue with the engine not turning off when the key is turned off? Any help would be appreciated sir.

[@Zuksoffroad]

Ignition switch internally broken. Unfortunately no Japan ignition switches available. RoadlessGear.com may have India made ignition switch.

[@ecowboys193]

Just installed a new ignition switch that had both pig tails on it. Same issue with one that only had the one pig tail?

[@Zuksoffroad]

@@ecowboys193 samurai ignition has the spring in the switch. So when you let go the key springs back. Is the cylinder dragging not allowing the switch at the end to release. When you say engine keeps running to mean to say there is voltage on the coil plus terminal on the black and white wire when you turn the key off?

[@Zuksoffroad]

Done typing tech support here please text me at [phone] unless you are international.

[@Zuksoffroad]

Or do you mean the engine diesels a bit before it shuts off when you turn the key.

[@santiagolopez2771]

Thank you!!!

[@Zuksoffroad]

You're welcome!

[@nancysavidge7611]

Does anyone know of a Denver shop that works on sami's? We specifically are looking for some suspension improvements. Thanks for any ideas.

[@Zuksoffroad]

The Spring Works is the only shop in CO that I recommend.

[@nancysavidge7611]

That is awesome I will call them.@@Zuksoffroad

[@Zuksoffroad]

The owner Brian is a long time Samurai owner. A brief phone call to me and I can explain all the suspensions systems available and the differences.

[@mora103]

Yj leafsprings and Toyota axles 😅

[@Zuksoffroad]

@@mora103 making hybrids because toy axles are getting rare but yea it’s a nice set up.

[@ju2067]

Awesome! Can't say how much I appreciate your sharing your years of knowledge! Engine troubleshooting videos would be great. I have a 1.3 EFI that surges on throttle, above 2500.... can't figure it out.

[@Zuksoffroad]

Great suggestion! I can explain that fix over the phone.

[@ju2067]

@@Zuksoffroad Thanks Myron, I'll get in touch hopefully sooner than later. It's been like this for a couple years sitting in my first buggy. Currently putting final touches on a Vitara 2.0 buggy so the EFI isn't so urgent at the moment.

[@samaxeman123]

Thanks for the video, I’ve always had an issue with a low coolant temp reading on factory dash, 1.6 16 valve swap. Reads just above cold line and remains there. Temp is all verified correct at thermostat housing. Maybe different coolant sender required for 1.6?

[@Zuksoffroad]

1.6 16v engines have a defective design and you should never trust the CH gauge on any 16v engine. Always on a 1.6 16v install a real analog needle temp gauge and watch it like a hawk. One day you might see your CH in the normal spot but your needle at 250. Shut it down immediately to save that engine. The same one tab sensor on this engine can not read steam like it can on 8v so the CH sensor is not to be trusted. It can read cool while the engine is melting the plastic and rubber connected to it.

[@samaxeman123]

@@Zuksoffroad Engine now has new head and rebuild after old head developed soft spots due to over heating and I did see the CH gauge go the normal line when it was over heating so that sure proves how unreliable it is. I now have an in hose sensor connected via the top radiator coolant hose plugged into a aftermarket needle gauge which shows 62 to 70 degrees celsius during running and I sure do keep an eye on it. Would be awesome to see some content on the 1.6 16 valve swap into samurai in future maybe. Thanks for reply.

[@Zuksoffroad]

@@samaxeman123 been trying to get out of Suzuki engines for awhile now. Getting harder and harder to find the parts. I stopped doing 16v last year and have only one more to install and it will probably be my last 1.6 16v swap. It’s a fragile engine.

[@samaxeman123]

@@Zuksoffroad parts are becoming very short in supply, I was lucky enough to score a g16 with 50000 miles on it and has the block stiffening plate between the crank caps so I’m hoping I will get some good years from it rallying in the sand dunes, I’m not sure if you get them in America but the m series Suzuki engines are a fantastic dohc choice that is becoming more common

[@Zuksoffroad]

I always recommend a real analog temp gauge on a 1.6 16v it’s a fragile engine and you can not trust the C-H in the cluster. Reason why is the 16v can not read steam. If the sensor is not in the coolant it will read cool when the engine kills itself. O’riely’s makes a inexpensive gauge with the adapter that allows a 1/4NPT tap above the green connector for EMC water temp. Check the coolant level every week.